Novel Low Cost Implementation of a High Efficiency Solar Electric System using existing Building Structures

ABSTRACT

A technique for easily and cost effectively installing solar photo-voltaic solar panels is provided. Solar panels are installed on pre-existing building structures to minimize the cost of installation. Pre-fabricated and field configurable components are used for mounting the solar panels such that the cost and ease of installation is made even more favorable to an average solar electricity consumer. An example of such a cost-effective implementation includes installing solar panels on pre-existing fences demarcating residences or commercial office spaces. L-shaped brackets are screwed on to the fence pillars. Pre-cut and adjustable aluminum or wooden rails are then mounted on the horizontal protruding arms of the L-shaped brackets. Solar photo-voltaic panels are later fitted on to the rails. Finally, quick disconnects are used to hook-up the solar panels to the DC-to-AC inverter in a desirable configuration to form the electrical circuit. The ease of the installation coupled with the elimination of the need for its professional know-how targets this method of installation for the general public without formal solar electricity installation training.

BACKGROUND OF INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to the installation of solar energysystems. More particularly, the present invention relations to theinstallation of solar electric systems on pre-existing buildingstructures, thereby simplifying the installation process and reducingits cost.

[0003] 2. Description of the Related Art

[0004] Harnessing energy from the sun has gained particular relevance inrecent times. As human population and its endeavors towards comforts andindustrialization, have grown rapidly in the latter part of the 20^(th)century, consequently have the demands on energy exploded in moderntimes. Traditional means of producing energy, particularly electricity,have also proven to be increasingly and prohibitively detrimental to theenvironment from inevitable production of carbon dioxide. Guaranteeingan uninterrupted supply of electricity has become challenging due tounreliable and often limited supply of raw materials such as, coal andwater.

[0005] These issues have generated tremendous interest in the researchand implementation of various alternate and renewable energy sources,such as wind, sun and natural gas. Although these sources of energy areessentially at no cost for production, in the past, their practicalimplementations have been cumbersome and expensive. However,particularly in the case of solar energy, advances in semiconductortechnology have made solar cells efficient and commercially viable.Arrays of solar cell panels can be aesthetically mounted over relativelysmall areas, to collect solar radiation. State government subsidies andfederal rebates in the United States make solar energy installations allthe more lucrative.

[0006] However, even with such advances in harnessing solar energy, itscommercial acceptance has been muted. Reasons cited for its slowacceptance include cost, limited availability of installation space,lack of professional installers, lack of public awareness, etc.

[0007] There is an upfront lump-sum equipment, labor and installationcost for a solar electric system, which is typically in excess of 80times the monthly electricity utility bill. Such a high lump sum amount,coupled with the relative acceptance of paying for electricity on amonthly basis, enforces the perception that solar electricity isexpensive and unaffordable. The clear financial benefits of solar energyover a longer term (typically a period greater than 5 years) are oftennot apparent to a potential customer.

[0008] Secondly, space is always a premium for home or commercial realestate owners. Installing solar panels on the ground is one option forthese solar electricity customers but it requires building strong enoughfoundations to withstand the forces of nature such as rain and wind.Installing solar panels on the roof of buildings is a second option. Thedifficulties and risks involved with working on roofs, which by defaultare well above the ground level, makes this option costly andchallenging. Therefore, there is always a trade-off customers have tomake between issues such as, losing precious ground space to a solarenergy installation, installation costs, benefits of solar energy,aesthetics of solar panels, etc.

[0009] The third issue is that of limited availability and consequently,high cost for professional installation of solar electric systems.Installing and implementing a solar electric system requires knowledgeof traditional skills such as building construction, roofing andelectrical wiring plus the high technology know-how of photo-voltaicsolar panels., inverters and other electronic components These twocompetency skills have traditionally been mutually exclusive from aprofessional standpoint—building contractors have not dealt with solarpanels and professionals who understand solar panels typically do notknow the specifics of building structures, roofing, etc. Professionalsand companies that offer solar electric system installation solutions bycombining these different skills, are therefore, few in number.Consequently, solar electric system installation as become a nichebusiness, thereby increasing installation cost to the consumer.

[0010] Lastly, there has been a general lack of awareness with respectto the use of solar energy for electricity generation. Common mythsinclude a misconception that solar electricity is only viable for largeutility power plants. Also some people think that solar electricitygeneration is similar to or is equally inefficient and/or cumbersome assolar heat absorption-based solar water heaters. There is also askepticism about the high technology associated with solar cells inphotovoltaic panels—do they really offer a commercially viablealternative to getting power from commercial utilities or are they justsomething overly optimistic and futuristic ideas that are far frommaturity. All these questions and trepidations have prevented theconsumer from realizing the true potential of solar generation ofelectricity.

[0011] However, in contrast to people's misconceptions, solar energyoffers good financial and environmental benefits to the masses. Forinstance, using United States Environmental Protection Agency (EPA)estimates and in approximate terms, the equivalent of 3000 Watts ofsolar energy-based photovoltaic system capacity, as is typically neededby a single family residence, conventional thermal electricityproduction releases harmful gases in the amounts of 7700 lbs of carbondioxide and 2 lbs of nitrogen oxides per year. The carbon dioxideemissions alone, are equal to the emissions of driving 9600 miles in anaverage passenger car or the carbon dioxide absorbed by approximately 1acre of trees in one year. Moreover, in the State of California, usingthe financial benefits of a 50% subsidy towards parts and labor of asolar electricity installation and a state income tax break of anadditional 15%, a consumer would have an one-time out-of-pocket expenseof $10500 but would not have to pay for electricity for the expected 40year life of the solar electric system. Alternately, financing thissolar electricity installation at a 6.5% per annum interest rate, a 30year term and a 35% income tax credit on the interest paid, would resultin a net monthly gain of $44. Therefore, increasing the mass acceptanceof solar electric systems is justified from a financial and anenvironmental stand-point.

[0012] To achieve this goal of making solar energy more appealing to thepublic for residential and commercial applications, it is necessary toaddress the challenges and issues mentioned above. Our invention reducesthe cost and simplifies the installation of solar electric systems whichshould result in their rapid acceptance by the masses. The details ofthis invention are presented next.

SUMMARY OF INVENTION

[0013] Broadly speaking, we propose an invention that simplifies theinstallation of solar electric systems and thereby increase their massacceptance.

[0014] In the first embodiment, our invention uses existing buildingstructures such as fences for installing solar electric panels.Pre-existing fences typically used for demarcating residentialboundaries are used as the basic building blocks for our easy solarinstallation. Medium or relatively heavy-duty L-shaped brackets arescrewed on to the top portion of the fence pillars. Pre-fabricated andconfigurable aluminum rails or wooden plates are then screwed on to thehorizontal legs of the L-shaped bracket. Solar photo-voltaic panels arethen fastened on to the rails or wooden plates. Finally, quickdisconnects are used to hook-up electrical wires to the solar panels ina pre-configured electrical circuit. The electrical circuit comprises ofsolar panels that generate DC electricity which is fed to a DC-to-ACinverter. The inverter feeds AC electricity through a power measuringmeter to a power grid. Considering the use of pre-existing buildingstructures such as fences, and commonly used and familiar componentssuch as brackets and screws, the elimination of the need to climb on toroofs and the installation ease of quick disconnects and flexible rails,it is mainly expected that the solar panel installation will be done bycustomers, themselves, with no professional training or know-how ofsolar system installation. In other words, our invention will offersolar energy installations in the form of a do-it-yourself kit for thegeneral public to implement.

[0015] In the second embodiment, we use easy to assemble instead ofpre-existing building structures for installing solar electric panels.Structures which can be put together easily include gazebos, patiocovers or window awnings. These structures are commercially available atreasonable prices and are also available in a variety of sizes, stylesand colors to suit a customer's needs and tastes. Pre-fabricated andconfigurable aluminum rails or wooden plates are screwed on to the topsurface of such structures. Solar electric panels are mounted on tothese rails and then electrically connected to a DC-to-AC inverter togenerate electricity.

BRIEF DESCRIPTION OF DRAWINGS

[0016]FIG. 1 is an overview of fence mounting for solar electric systemembodiment of the present invention.

[0017]FIG. 2 is an overview of fence mounting as solar electric systemwith photovoltaic panels mounted.

[0018]FIG. 3 is a detailed diagram of a “L”bracket assembly embodimentof the present invention showing attachments to the post of the fence.

[0019]FIG. 4 is a top view of the full fence mounted solar electricsystem with the electrical attachments to the building.

[0020]FIG. 5 is a bottom view of the photovoltaic panels mechanical andelectrical attachments.

[0021]FIG. 6

DETAILED DESCRIPTION

[0022]FIG. 1 illustrates the side view of the preferred embodiment ofour present invention of a fence as a pre-existing building structureused for mounting a solar electric system. In this figure, we show asection of such a fence which extends and repeats towards the left andright of the paper. It includes the typical elements of a fence, such aspillars, 100, which are rigidly planted in the ground, and wooden planksor panels, 110, which are fixed alongside each other between the fencepillars, 100. Pillars, 100, and panels, 110, form the basis of mostfences. The modifications, we propose, include attaching the verticalarms of a L-shaped bracket, 102, to the fence pillars, using screws,106. Adjustable and configurable rails, 104, are then fastened to thehorizontal arms of the L-shaped brackets, 102, using screws, 108.

[0023]FIG. 2 shows an enlarged and more detailed view of the elementswhich are key to our invention. The L-shaped bracket is illustrated as202, with screws, 204 used to attach the vertical arm, 212 of thebracket to pillar, 200. To better support the horizontal arm, 214, ofthe bracket and reinforce the corner joint of the “L” in the bracket, anangled arm, 210 is used and is welded or joined at the ends to thevertical and horizontal arms. Finally, this figure shows horizontalrails, 208, are mounted on the horizontal arm, 214, of the bracket usingscrews, 206.

[0024] A solar panel installation is demonstrated in side view in FIG.3. As previously described in FIG. 1 or 2, fence elements namely,pillars, 300, and fence panels, 308, are shown in this figure. Alsoincluded is the L-shaped bracket, 304, and the horizontal rails, 306.Additionally, shown in this figure are solar electric photo-voltaicpanels, 302, which are mounted easily on the rails, 306. The solarpanels are typically mounted flush with the top edge of the fence panelsand are orthogonal (90 degrees angle) to the fence pillars. Consideringthat the fence panels are typically the height of an average person, thesolar panels are approximately just above (3 to 6 inches) the eye levelfor a standing person and are therefore, barely visible in side view.This makes the solar panel installation, non-intrusive from an aestheticstandpoint.

[0025]FIG. 4 shows the plan view of the solar panel installation lookingbottom-up from the ground. The fence pillar is shown in cross-sectionalview by notation, 414. The horizontal adjustable rails, 408, areattached to the horizontal arms of the L-shaped brackets, 416, withscrews, 412. The solar panels, 400, are shown mounted on the rails, 408using screws or quick disconnect fasteners, 410. The electricalconnections are made using wiring harnesses, 404, traversing frompanel-to-panel and finally, to the inverter (not shown). 402 is theelectrical connection box for each of the solar panels, and is attachedto the under surface of the panels by the panel manufacturers. Usingquick electrical disconnects, 406, the wiring harnesses, 404, and panelconnection boxes, 402 are electrically hooked up in a desiredpre-configured circuit.

[0026]FIG. 5 shows the block diagram of typical electrical connectionsfor a solar electric system. A house or a commercial site where solarelectricity is being generated using our invention, is denoted as 500. Abank of solar panels, 502, mounted on a fence, is also shown. 504 is aDC disconnect switch connects the end solar panel to the inverter, 508,using electrical wires, 506. The DC disconnect switch, which istypically mounted on a fence pillar, is used to isolate the solar panelselectrically from the inverter for preventive maintenance or ifrequired, in an emergency. Electrically downstream to the inverter is anAC disconnect switch, 510, which further connects to a two-wayelectricity usage meter, 512. The AC disconnect switch, 510 is used toisolate the solar electricity generation unit comprised of elements,502, 504, 506 and 510, from the power grid, 514, whenever desired or inan emergency. On the other end, the meter, 512 connects to theelectricity utility power grid. The meter quantifies the amount ofelectricity supplied to the grid and used from the grid and is used bythe individual solar electricity generator and the utility company todetermine the net rebates or charges between the two of them. Theinverter, AC disconnect switch and the two-way electricity usage meterare typically mounted on a rack on an inner wall in the garage of ahouse or a utility room of a commercial site.

[0027] The various components of a solar electric installation using ourinvention are illustrated as a schematic in FIG. 6, for further clarity.A house or a commercial site where solar electricity is being generated,is denoted in this figure as 620. Fence pillars in this figure aredenoted as 600 whereas fence panels are shown by the notation 604. AL-shaped bracket. The horizontal adjustable rails, 606, are attached tothe horizontal arms of the L-shaped bracket, and solar panels, 608 areaffixed to these rails. The solar panels are electrically connected in apre-decided configuration and feed in to the DC disconnect switch, 612.Electrical wires, 610, connect the DC disconnect switch to an inverter,614. Electrically downstream to the inverter is the AC disconnectswitch, 616, followed by the two-way electricity usage meter, 618. Themeter is connected at the other end to the utility power grid.

[0028] As described in the “Summary of Invention” section, an alternateembodiment involves solar panel installations on easy-to-assemblestructures, as shown in FIG. 7. An example of such a structure is agazebo, as denoted by 702. In this case, the gazebo is a free standingstructure, placed outside the house or commercial site, 716. Solarpanels, 700, are mounted on the gazebo, using adjustable rails, 704.These photo-voltaic panels generate DC electricity and feed it through aDC disconnect switch, 708, and electrical wires, 706 to the inverter,710. Similar to the preferred embodiment and as described in FIG. 6, theinverter, 710 connects to an AC disconnect switch, 712, a two-wayelectricity usage meter, 714, and finally to the power grid, 716.

We claim in this invention:
 1. A method for installing solar energysystems, the method comprising: using pre-existing building structuresas the basic load-bearing structures for such an installation;installing solar energy systems on these existing structures.
 2. Amethod for installing solar energy systems as recited in claim 1,wherein the basic building structure is a fence such as those used fordemarcating boundaries between residential or commercial plots.
 3. Amethod for installing solar energy systems as recited in claim 1, wherein the solar energy system is selected from a group of solar electricsystems or solar heating systems.
 4. A method for installing solarenergy systems as recited in claim 3, wherein the solar electric systemscomprises of arrays of solar photo voltaic cells to form larger panels.5. A method for installing solar energy systems, the method comprising:using pre-existing building structures as the basic load-bearingstructures for such an installation; using a plurality of connectors andjoints to fasten to the building structures; mounting adjustable railson to the connectors; installing solar panels on these rails; andconnecting the solar panels in a desired electrical circuit to generateelectricity.
 6. A method for installing solar energy systems as recitedin claim 5, wherein the basic building structure is a fence such asthose used for demarcating boundaries between residential or commercialplots.
 7. A method for installing solar energy systems as recited inclaim 5, wherein the solar panels are comprised of a single solarphoto-voltaic cell or an array of solar photo-voltaic cells.
 8. A methodfor installing solar energy systems as recited in claim 5, wherein theconnectors are L-shaped brackets made of materials selected from a groupof aluminum, iron, their composites and wood.
 9. A method for installingsolar energy systems as recited in claim 5, wherein the adjustable railsare made of materials selected from a group of aluminum, iron, theircomposites and wood.
 10. A method for installing solar energy systems asrecited in claim 5, wherein the solar panels are installed on the railsusing fasteners such as screws and nuts and bolts or usingquick-disconnect fasteners.
 11. A method for installing solar energysystems as recited in claim 5, wherein the solar panels are electricallyconnected to a DC-to-AC inverter to generate electricity for household,institutional or commercial use.
 12. A method for installing solarenergy systems, the method comprising: using easy-to assemble buildingstructures as the basic load-bearing structures for such aninstallation; using a plurality of connectors and joints to fasten tothe building structures; mounting adjustable rails on to the connectors;installing solar panels on these rails; and connecting the solar panelsin a desired electrical circuit to generate electricity.
 13. A methodfor installing solar energy systems as recited in claim 12, wherein thebasic building structure is selected from a group that includes but isnot limited to a gazebo, a patio cover and a window awning.
 14. A methodfor installing solar energy systems as recited in claim 12, wherein thesolar panels are comprised of a single solar photo-voltaic cell or anarray of solar photo-voltaic cells.
 15. A method for installing solarenergy systems as recited in claim 12, wherein the connectors areL-shaped brackets made of materials selected from a group of aluminum,iron, their composites and wood.
 16. A method for installing solarenergy systems as recited in claim 12, wherein the adjustable rails aremade of materials selected from a group of aluminum, iron, theircomposites and wood.
 17. A method for installing solar energy systems asrecited in claim 12, wherein the solar panels are installed on the railsusing fasteners such as screws and nuts and bolts or usingquick-disconnect fasteners.
 18. A method for installing solar energysystems as recited in claim 12, wherein the solar panels areelectrically connected to a DC-to-AC inverter to generate electricityfor household, institutional or commercial use.